US4656082A - Laminate material with fibrous inner layer - Google Patents
Laminate material with fibrous inner layer Download PDFInfo
- Publication number
- US4656082A US4656082A US06/770,395 US77039585A US4656082A US 4656082 A US4656082 A US 4656082A US 77039585 A US77039585 A US 77039585A US 4656082 A US4656082 A US 4656082A
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- material according
- laminate material
- laminate
- layer
- adhesive
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- Expired - Lifetime
Links
- 239000002648 laminated material Substances 0.000 title claims abstract description 24
- 239000011888 foil Substances 0.000 claims abstract description 30
- 239000002657 fibrous material Substances 0.000 claims abstract description 15
- 239000002184 metal Substances 0.000 claims abstract description 14
- 229910052751 metal Inorganic materials 0.000 claims abstract description 14
- 238000010276 construction Methods 0.000 claims abstract description 5
- 239000000853 adhesive Substances 0.000 claims description 56
- 230000001070 adhesive effect Effects 0.000 claims description 56
- 239000000123 paper Substances 0.000 claims description 22
- 229920000098 polyolefin Polymers 0.000 claims description 15
- 238000001125 extrusion Methods 0.000 claims description 11
- 239000004744 fabric Substances 0.000 claims description 11
- 239000002655 kraft paper Substances 0.000 claims description 10
- 239000003063 flame retardant Substances 0.000 claims description 9
- 239000005030 aluminium foil Substances 0.000 claims description 8
- 239000000835 fiber Substances 0.000 claims description 5
- 229910000410 antimony oxide Inorganic materials 0.000 claims description 4
- VTRUBDSFZJNXHI-UHFFFAOYSA-N oxoantimony Chemical compound [Sb]=O VTRUBDSFZJNXHI-UHFFFAOYSA-N 0.000 claims description 4
- 239000012188 paraffin wax Substances 0.000 claims description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 239000005018 casein Substances 0.000 claims description 3
- BECPQYXYKAMYBN-UHFFFAOYSA-N casein, tech. Chemical compound NCCCCC(C(O)=O)N=C(O)C(CC(O)=O)N=C(O)C(CCC(O)=N)N=C(O)C(CC(C)C)N=C(O)C(CCC(O)=O)N=C(O)C(CC(O)=O)N=C(O)C(CCC(O)=O)N=C(O)C(C(C)O)N=C(O)C(CCC(O)=N)N=C(O)C(CCC(O)=N)N=C(O)C(CCC(O)=N)N=C(O)C(CCC(O)=O)N=C(O)C(CCC(O)=O)N=C(O)C(COP(O)(O)=O)N=C(O)C(CCC(O)=N)N=C(O)C(N)CC1=CC=CC=C1 BECPQYXYKAMYBN-UHFFFAOYSA-N 0.000 claims description 3
- 235000021240 caseins Nutrition 0.000 claims description 3
- 239000011152 fibreglass Substances 0.000 claims description 3
- 239000004816 latex Substances 0.000 claims description 3
- 229920000126 latex Polymers 0.000 claims description 3
- 229920001084 poly(chloroprene) Polymers 0.000 claims description 3
- 239000012815 thermoplastic material Substances 0.000 claims description 3
- 239000000463 material Substances 0.000 abstract description 8
- 239000010410 layer Substances 0.000 description 84
- -1 flameretardant compound Chemical class 0.000 description 12
- 238000009413 insulation Methods 0.000 description 12
- 239000004743 Polypropylene Substances 0.000 description 7
- 229920001155 polypropylene Polymers 0.000 description 7
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 6
- 238000000429 assembly Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000011118 polyvinyl acetate Substances 0.000 description 5
- 239000004698 Polyethylene Substances 0.000 description 4
- 229920000573 polyethylene Polymers 0.000 description 4
- 229920002689 polyvinyl acetate Polymers 0.000 description 4
- 229920001169 thermoplastic Polymers 0.000 description 4
- 239000004416 thermosoftening plastic Substances 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000009977 dual effect Effects 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 238000002310 reflectometry Methods 0.000 description 2
- 238000007763 reverse roll coating Methods 0.000 description 2
- 239000002759 woven fabric Substances 0.000 description 2
- 101100493710 Caenorhabditis elegans bath-40 gene Proteins 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/12—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
- E04D12/002—Sheets of flexible material, e.g. roofing tile underlay
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/54—Yield strength; Tensile strength
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/582—Tearability
- B32B2307/5825—Tear resistant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/12—Paper, e.g. cardboard
- B32B2317/122—Kraft paper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
- B32B2419/06—Roofs, roof membranes
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B2001/7691—Heat reflecting layers or coatings
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3382—Including a free metal or alloy constituent
- Y10T442/3415—Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the woven fabric]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/654—Including a free metal or alloy constituent
- Y10T442/656—Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the nonwoven fabric]
Definitions
- This invention relates to an improved laminate material.
- a safety mesh gives rise to a significant cost factor. This is due to the added installation cost, but also to the material cost since it normally is impractical to remove the mesh for subsequent re-use. Also, unless foil or other insulation is installed prior to the safety mesh, the presence of the latter can complicate subsequent installation of insulation.
- the present invention seeks to provide an improved laminate material suitable for use in place of a steel safety mesh. At least in a preferred form, the laminate of the invention also is able to serve as reflective insulation suitable for insulating the roof of a building.
- a laminate according to the invention has at least three layers, with at least one inner layer comprising a fibrous layer adhesively bonded to each of the next adjacent layers; with the next adjacent layers being of paper or metal foil.
- the fibrous layer which may be woven or non-woven, may have a density of from about 30 to about 150 g/m 2 and comprise fibres of from about 30 to about 150 tex.
- the fibres most preferably are from about 50 to 100 tex and in a layer of from about 50 to about 120 g/m 2 .
- the fibres may be of polymeric material, such as a thermoplastic material; polyolefin fibres being particularly preferred.
- the fibres may be of fibre-glass or carbon filament, preferably resin bonded, or of polyester fibre preferably a woven or spun bonded polyester.
- the fibrous layer may comprise cross-laminated airy fabric, formed from split film which is stretched tentered and heat bonded to a similar cross-layer.
- the fibrous layer can comprise a mixture of fibres of two or more such fibrous materials, while it also can include at least a minor percentage of natural or mineral fibrous material.
- the fibrous material may be biaxially oriented, for increased strength.
- the fibrous layer is woven material.
- the laminate may have at least one layer of paper and at least one metal foil layer, with there preferably being two each of those layers.
- the laminate may comprise an inner layer of fibrous material, with a paper layer over each major surface of that layer and a metal foil layer over the outermost major surface of at least one of the paper layers. Preferably, there is a respective metal foil layer over that surface of each layer.
- the respective layers of the laminate are each adhesively bonded together by means of a layer of film of a suitable adhesive material. This may be achieved in successive stages, with each layer being bonded in turn to a preceding layer. Preferably, at least one sub-assembly of two or more layers may be formed in an initial stage and further layers or sub-assemblies adhesively bonded thereto.
- two sub-assemblies each comprising a paper layer and a metal foil layer, can be used; with a fibrous layer being adhesively bonded to the paper layer of one sub-assembly and thereafter the paper layer of the other sub-assembly.
- Such procedure has the advantage of enabling preforming of the sub-assemblies, which can be stored in roll form, prior to adhesive bonding of the other sub-assembly, if required.
- the adhesive by which at least two adjacent layers of the laminate are bonded together may be of a flame-retardant grade, preferably applied by reverse roll coating.
- the fibrous layer comprises or includes thermoplastic fibrous material
- the adhesive by which that layer is bonded to at least one adjacent layer preferably is of that grade and/or type.
- the flame-retardant adhesive most preferably is a chlorinated paraffin containing antimony oxide or an alternative flameretardant compound dispersed or incorporated therein.
- a flame-retardant grade of adhesive such as a chlorinated paraffin including antimony oxide
- an adhesive such as detailed in the preceding paragraph preferably is used for bonding the other side of the fibrous layer to its adjacent layer.
- a polyolefin adhesive applied by an extrusion coater most preferably is used.
- the fibrous layer is a polyolefin
- a particularly preferred laminate according to the invention comprises the following layers and adhesives:
- the 10 ⁇ 6 polypropylene weave designates a woven polypropylene fabric having 10 yarn ends per inch in the warp (or machine direction) and 6 yarn ends per inch in the weft (cross direction). While the fabric can vary widely in this regard, the parameter of number of yarns per inch is important. Most preferably for a polyolefin, such as polypropylene or polyethylene, at least a 6 ⁇ 4 woven fabric or its equivalent in a non-woven fabric is used; and, while a 20 ⁇ 20 or higher woven fabric or non-woven equivalent can be used, it normally is not necessary to go beyond a 16 ⁇ 16 fabric or non-woven equivalent. Essentially the same number of yarns per inch can be used for a polyester fabric and an equivalent cross-laminated airy fabric, and also to non-woven equivalents for fibre-glass and carbon filament.
- the laminate is formed, preferably using conventional apparatus, by first bonding layers 1 and 3, by application of adhesive 2. Thereafter, layer 5 is applied over layer 3 as adhesive 4 is extruded therebetween by an extrusion coater to bond layers 3 and 5 together. After bonding together layers 7 and 9, by application of adhesive 8, layers 5 and 6 are bonded together by application of adhesive 6. As will be appreciated, bonding of layers 7 and 9 by adhesive 8 may be performed at any convenient time, either before, during or after producing a sub-structure comprising layers 1, 3 and 5 bonded by adhesive 2 and film 4. Numbers 1, 3, 5, 7 and 9 correspond to respective layers 12, 16, 22, 24 and 28 described hereinafter with reference to FIG. 1. Numbers 2, 4, 6 and 8 similarly correspond to respective adhesive layers 18, 20, 26 and 30 of FIG. 1.
- one of the layers 3, 7 can be omitted, with corresponding omission of adhesive 2 or 8, respectively.
- the resultant laminate then is more prone to cracking of the respective foil layer 1 or 9 which is not directly supported by having a paper layer bonded directly thereto.
- adhesives 2, 8 may be the same, whether a PVA adhesive, or a polyethylene adhesive.
- one or both of adhesives 2, 8 can be substituted by alternative adhesive such as detailed herein.
- adhesive 4 can be omitted, with bonding between layers 3, 5 being by means of a flame-retardant adhesive as used for adhesive 6; such variant enabling a reduction in the amount of adhesive 6 between layers 5, 7 provided that over all flameretardancy for the laminate is retained.
- FIG. 1 schematically shows a laminate in crosssection; the showing thereof being on a greatly enlarged scale
- FIG. 2 illustrates one arrangement for manufacturing a laminate as shown in FIG. 1.
- the laminate 10 comprises an upper layer of aluminium foil 12, the top surface of which is provided with a thin coating 14 of ink or dye so as to reduce its reflectivity.
- Foil 12 is bonded to a layer of Kraft paper 16 by adhesive 18, such as a PVA adhesive.
- Layer of paper 16 is bonded by polyolefin adhesive 20 to a layer 22 of polyolefin fibrous material, layer 22 preferably being woven.
- the surface of layer 22 remote from adhesive 20 is bonded to a second layer of Kraft paper 24 by adhesive 26; the latter preferably being a fire-retardant grade.
- the laminate is completed by a second layer of aluminium foil 28, bonded to the layer of paper 24 by polyolefin adhesive 30.
- Laminate 10 preferably is formed in an overall operation as depicted in FIG. 2, in which reference numerals of FIG. 1 have the same significance.
- foil 12 having coating 14 previously applied to its outer surface
- Foil 12 then is reversed over the upper one of rollers 34 to pass through the nip of combiner rollers 38.
- the lower one of rollers 34 rotates in bath 40 and takes up PVA adhesive from the latter for application to foil 12.
- paper 16 is drawn from supply roll 42 and passes through the nip of rollers 38 for application against adhesive applied to foil 12.
- Paper 16 and foil 12 pass from rollers 38 through drying oven 44, to cure adhesive 18 therebetween to form laminate sub-assembly 46.
- Sub-assembly 46 passes from oven 44, through the nip of rollers 48 of extrusion coater 50. Simultaneously, polypropylene fabric 22 is drawn from supply roll 52, and also passes through the nip of rollers 48. An extruder 54 of coater 50 extrudes a film 20 of polypropylene between the surface of paper 16, remote from foil 16, and the adjacent surface of fabric 22. Sub-assembly 46, fabric 22 and polypropylene film 20 therebetween thus is consolidated by rollers 48 to form laminate sub-assembly 56.
- Kraft paper 24 and aluminium foil 28 each is drawn from respective supply roll 58,60.
- Each of paper 24 and foil 28 pass through the nip of rollers 62 of extrusion coater 64.
- extruder 66 of coater 64 extrudes a film 30 of polyethylene toward the nip of rollers 62, between the opposed surfaces of paper 24 and foil 28; film 30 being consolidated with paper 24 and foil 28 to form laminate subassembly 68.
- sub-assembly 68 passes over guide roller 70, and around roller 72 to reverse roll coater 74.
- the later has central and upper rollers 76,78 at the nip of which dam 80 holds a supply of flame-retardant adhesive, such as a chlorinated paraffin containing antimony oxide.
- Rollers 76,78 are reversely driven, with roller 76 rotating oppositely to sub-assembly 68 as the latter passes through the nip between roller 76 and a lower roller 82.
- Roller 78 acts to meter adhesive 26 carried from dam 80 on roller 76; with the adhesive then being applied to the paper 24 of subassembly 68.
- Sub-assembly 56 passes from extrusion coater 50, over roller 84, through the nip of combiner rollers 86; fabric 22 of sub-assembly being lower-most.
- Sub-assembly 68 passes from reverse roll coater 74, through the nip of rollers 86, with adhesive 26 uppermost. Rollers 86 consolidate subassemblies 56, 68 and adhesive 26 therebetween, to form laminate 10 which passes to take up roll 88.
- sub-assembly 46 could pass from oven 44 to a take-up roll for later use; while sub-assembly 68 similarly could pass to a take-up roll; the two sub-assemblies 46,68 subsequently being used to form laminate 10 in a third stage in which sub-assembly 68 is first passed through reverse roll coater 74.
- production of sub-assembly 46 can be followed, as described, to production of a subassembly 56; with the latter and sub-assembly 68 being formed prior to such third stage.
- sub-assemblies 46, 56, 68 need be produced in a first stage; with subsequent production through to formation of laminate 10 following in a second stage.
- sub-assembly 46 can be replaced by a second quantity of sub-assembly 68, or vice versa.
- FIG. 1 approximates relative thicknesses of components of laminate 10 (albeit on an enlarged scale), thicknesses and increases thereof are not depicted in FIG. 2.
- the laminate of the invention has superior properties compared with a laminate formed of similar layers and differing only in that it does not include a fibrous layer.
- the laminate of the invention shows, for example, superior results in the Beach puncture test, as well as having superior tensile strength and elongation, and exhibiting markedly superior tear resistance as measured by standard P.P.T. and edge tear tests. Where the laminate is produced on a machine providing continuous lengths of the laminate, the superior tensile strength, elongation and tear resistance is achieved in both the machine direction and cross direction. The laminate also displays a high resistance to delamination.
- the laminate also exhibits in standard tests, conducted in accordance with AS 1530, a very low flame spread factor, and an excellent heat factor and flammability index. As will be appreciated, performance in these tests is enhanced by use of flame resistant grade adhesive as detailed above.
- a laminate according to the invention particularly where provided with at least one outer layer of metal foil such as aluminium foil, is well suited to use as roofing insulation and/or sarking. In such application, its superior strength can be particularly advantageous.
- the strength of the laminate of the present invention is such that its use as roofing insulation and/or sarking, in place of conventional reflective foil laminate, enables such safety mesh to be dispensed with. That is, the laminate of the invention, particularly where the fibrous layer comprises woven thermoplastic fibers, has a strength providing equivalent safety for roof tilers to that afforded by the conventional safety mesh.
- the laminate thus is useful in providing the dual function of roofing insulation and a safety layer, but at a significant overall cost saving both in material cost and in avoidance of the need for installation cost for the safety mesh.
- the form of weave can vary. That is, the material can be of open, mesh form or it can be closely woven. Also, the fiber used can vary in denier with both the thickness of the fibrous layer and mesh form required, so as to achieve an overall balance of tensile strength, thickness and cost for the resultant laminate.
Abstract
Description
______________________________________ 1. Aluminum foil 7.5 μm 20.3 g/m.sup.2 2. Polyvinyl acetate adhesive 1.5 g/m.sup.2 3. Kraft paper 39.0 g/m.sup.2 4. Polyproylene extrusion 35.0 g/m.sup.2 5. 10 × 6 Polypropylene weave 79.0 g/m.sup.2 6. Flame retardant adhesive 250.0 g/m.sup.2 7. Kraft paper 39.0 g/m.sup.2 8. Polyethylene adhesive 7.0 g/m.sup.2 9. Aluminum foil 7.5 μm 20.3 g/m.sup.2 491.1 g/m.sup.2 ______________________________________
Claims (20)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AUPG695984 | 1984-09-05 | ||
AUPG6959 | 1984-09-05 | ||
AU46942/85A AU570338B2 (en) | 1984-09-05 | 1985-09-05 | Laminate material |
Publications (1)
Publication Number | Publication Date |
---|---|
US4656082A true US4656082A (en) | 1987-04-07 |
Family
ID=25627708
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US06/770,395 Expired - Lifetime US4656082A (en) | 1984-09-05 | 1985-08-28 | Laminate material with fibrous inner layer |
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US (1) | US4656082A (en) |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5182162A (en) * | 1990-10-24 | 1993-01-26 | Amoco Corporation | Self-bonded nonwoven web and net-like web composites |
US5185201A (en) * | 1990-07-31 | 1993-02-09 | Georgia-Pacific Corporation | Laminates for protecting incompletely dry surfaces |
US5652041A (en) * | 1993-09-01 | 1997-07-29 | Buerger; Gernot K. | Nonwoven composite material and method for making same |
EP1268194A1 (en) * | 2000-02-10 | 2003-01-02 | Mark M. Friedman | Flexible reflective insulating structures |
US20120202026A1 (en) * | 2009-11-23 | 2012-08-09 | Sang-Keun Lee | Roof-greening sheet |
US9528261B2 (en) * | 2013-01-09 | 2016-12-27 | Vita Nonwovens, Llc | Synthetic fiber insulation with facing |
US20200399904A1 (en) * | 2019-06-24 | 2020-12-24 | Owens Corning Intellectual Capital, Llc | Roofing underlayment with hydrophobic nonwoven core |
US11441316B2 (en) * | 2020-10-30 | 2022-09-13 | Bmic Llc | Self-adhered roofing systems and methods |
WO2022198258A1 (en) * | 2021-03-20 | 2022-09-29 | Australian Thermal Insulation Manufacturers Pty Ltd | A passive fall prevention device |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB996909A (en) * | 1960-09-22 | 1965-06-30 | Etablissements D. Ducarin | |
GB1011342A (en) * | 1963-05-14 | 1965-11-24 | Paper Sacks Ltd | Laminated material |
AU275666A (en) * | 1965-03-12 | 1967-09-14 | Scovill Manufacturing Company | Slidin g clasp fastener |
GB2102731A (en) * | 1981-07-23 | 1983-02-09 | Ruberoid Paper Limited | Flexible and rollable sheet material |
-
1985
- 1985-08-28 US US06/770,395 patent/US4656082A/en not_active Expired - Lifetime
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB996909A (en) * | 1960-09-22 | 1965-06-30 | Etablissements D. Ducarin | |
GB1011342A (en) * | 1963-05-14 | 1965-11-24 | Paper Sacks Ltd | Laminated material |
AU275666A (en) * | 1965-03-12 | 1967-09-14 | Scovill Manufacturing Company | Slidin g clasp fastener |
GB2102731A (en) * | 1981-07-23 | 1983-02-09 | Ruberoid Paper Limited | Flexible and rollable sheet material |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5185201A (en) * | 1990-07-31 | 1993-02-09 | Georgia-Pacific Corporation | Laminates for protecting incompletely dry surfaces |
US5182162A (en) * | 1990-10-24 | 1993-01-26 | Amoco Corporation | Self-bonded nonwoven web and net-like web composites |
US5652041A (en) * | 1993-09-01 | 1997-07-29 | Buerger; Gernot K. | Nonwoven composite material and method for making same |
EP1268194A1 (en) * | 2000-02-10 | 2003-01-02 | Mark M. Friedman | Flexible reflective insulating structures |
EP1268194A4 (en) * | 2000-02-10 | 2003-05-02 | Raphael Heifetz | Flexible reflective insulating structures |
EP2505733A1 (en) * | 2009-11-23 | 2012-10-03 | Renew System Co. Ltd | Roof-greening sheet |
US20120202026A1 (en) * | 2009-11-23 | 2012-08-09 | Sang-Keun Lee | Roof-greening sheet |
EP2505733A4 (en) * | 2009-11-23 | 2014-01-22 | Renew System Co Ltd | Roof-greening sheet |
US9528261B2 (en) * | 2013-01-09 | 2016-12-27 | Vita Nonwovens, Llc | Synthetic fiber insulation with facing |
US20200399904A1 (en) * | 2019-06-24 | 2020-12-24 | Owens Corning Intellectual Capital, Llc | Roofing underlayment with hydrophobic nonwoven core |
US11518137B2 (en) * | 2019-06-24 | 2022-12-06 | Owens Corning Intellectual Capital, Llc | Roofing underlayment with hydrophobic nonwoven core |
US11441316B2 (en) * | 2020-10-30 | 2022-09-13 | Bmic Llc | Self-adhered roofing systems and methods |
WO2022198258A1 (en) * | 2021-03-20 | 2022-09-29 | Australian Thermal Insulation Manufacturers Pty Ltd | A passive fall prevention device |
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